Pipeline Corrosion Research Articles

Global trends in technologies and nanomaterials for removal of sulfur organic compounds: Clean energy and green environment

• Various Technologies for sulfur organic compounds removal from fuels were reviewed. • Several nanomaterials used in desulfurization of thiophenes were discussed. • Trending catalysts used in hydrodesulfurization of thiophenes were reviewed. • Trends in desulfurization technologies to achieve complete sulfur removal were highlighted. Sulfur compounds, which commonly exist in substantial amounts in produced oil, gasoline, diesel, and jet fuel, cause a wide range of negative consequences including pollution, reduced engine efficiency, severe corrosion of pipelines, reactors, and equipment, as well as the poisoning of catalysts. Consequently, strict environmental rules and constraints are in place to keep the amount of sulfur in the air to a bare minimum. To achieve this objective, desulfurization or removal of sulfur is applied commonly in most refinery plants. In this review, numerous methods, adsorbents and catalysts used for the elimination of sulfur compounds are investigated. The review presents an overview of the emerging technologies for ultra-deep desulfurization to obtain ultra-low-sulfur fuels. The development of robust adsorbents and nanomaterials with ideal regeneration approaches is required to establish the capabilities of desulfurization processes. This review is expected to provide essential references and future directions for developing desulfurization technologies and materials for practical applications.

Pipe Line Inspection Robot

Abstract: Pipelines are mainly constructed to transport all kinds of fluids and gases. Many accidents had occurred from fluid leaks because of cracks and corrosion of pipelines. To eliminate or minimize the accidents periodical inspection of pipelines should be done. Analysis and control of autonomous robot for pipeline inspection requires design and model of a robot equipped with the proper sensors. This project deals with the design, modelling (software) and simulation of pipeline inspection robot. The robot is an autonomous mobile robot. The robot is placed at the entrance of the pipe, by giving suitable commands it will move forward and inspect the defects inside the pipe. This inspection robot includes camera for visual inspection to identify the cracks and corrosion in pipe. It captures the inner images of the pipe for further investigation. This robot also includes a LIDAR sensor for mapping of the pipe. The mapping and navigation are all done in ROS (Robot Operating System) with help of Gazebo and Rviz. The design of the robot is created in Fusion 360 and then it is transferred into Gazebo. The simulation of robot is done in circular pipes.

Microbiologically influenced corrosion of wastewater pipeline and its mitigation by phytochemicals: Mechanistic evaluation based on spectroscopic, microscopic and theoretical analyses

A wastewater pipeline network is an essential infrastructure for social viability and economical sustainability. The corrosion of pipeline infrastructure can lead to leakage/outflow of toxic materials and pollute the environment, including water bodies. Sulfate-reducing bacteria (SRB) are primarily accountable for the corrosion of wastewater pipelines. The present study reveals microbiologically influenced corrosion (MIC) by a newly isolated SRB, i.e., Klebsiella pneumoniae (IIP-C3), from the wastewater pipelines over the mild steel surface. The IIP-C3 formed a bio-film over the mild steel surface. The FeS-based polymorphous materials are produced at bio-interface by reducing inorganic sulfates, which are readily oxidized/hydrolyzed to metal oxide as corrosion products. The methanolic extracts of Capsicum annuum (CA), Zingiber officinale (ZO), and Foeniculum vulgare (FV) are selected based on their antimicrobial activities. The ZO, FV, and CA-based protective coatings showed 91.1%, 77.2%, and 72.7% corrosion mitigation efficiencies for mild steel. The mechanistic interpretation of MIC and its mitigation based on the molecular structure of phytochemicals of plant extracts are further supported by molecular orbital theory. The application of plant extracts suppressed the bio-film growth and minimized the corrosion of mild steel. The present work represents the potential of phytochemicals as alternatives to toxic biocides to mitigate MIC.

Facile Synthesis and Characterization of CeO2-Nanoparticle-Loaded Carboxymethyl Cellulose as Efficient Protective Films for Mild Steel: A Comparative Study of Experiential and Computational Findings.

Corrosion is considered to be the most severe problem facing alloys and metals, one that causes potentially dangerous industrial issues such as the deterioration of buildings and machinery, and corrosion in factory tanks and pipelines in petroleum refineries, leading to limited lifetime and weak efficacy of such systems. In this work, novel CeO2-nanoparticle-loaded carboxymethyl cellulose (CMC) was successfully prepared by using a simple method. The structural configuration of the prepared CeO2-nanoparticle-loaded CMC was investigated by FE-SEM/EDX, TEM, FT-IR, and thermal analyses. The corrosion protection proficiency of uncoated and coated mild steel with CeO2-CMC systems in 1.0 M HCl solutions was studied by EOCP-time, EIS, and PDP tools. Moreover, the relationship between the structure of coating films and their corrosion protection was confirmed by DFT calculation and MC simulation. The obtained findings from the studied methods showed that the prepared CeO2-CMC-coated films reported high corrosion resistance. The protection capacity augmented with ceria presents an increase of up to 3% to achieve 98.4%. DFT calculation and MC simulation confirmed the influence of the chemical construction of coated films on its protection capacity, which was in accordance with the experimental results.

USE OF GLASS REINFORCED EPOXY PIPE IN PLACE OF CARBON STEEL PIPE IN NIGER DELTA.

This research work uses gravimetric analysis for corrosion tests performed to determine the weight loss and corrosion extent on carbon steel and glass reinforced epoxy (GRE) specimens. Comparative results for both specimens are analysed to justify the use of glass reinforced epoxy pipe as an effective control measure for the corrosion of oil pipelines used for the transportation of hydrocarbon products. The values obtained from the experiment are used to develop regression model which can be helpful to predict the corrosion extents on both materials within the test composition. Coefficient of determination is explored to ascertain the reliability of the regression models. The results obtained indicated that 99 percent of the original uncertainty has been explained by the regression models. From the experimental results, glass reinforced epoxy test specimens had better resistant to corrosion than carbon steel test specimens which makes it attractive alternative to the conventional carbon steel pipe for the transportation of hydrocarbon products in the Niger Delta of Nigeria. Keywords: Carbon steel, Corrosion extent, Gravimetric analysis, GRE, Regression models.

Catalytic Steam Reforming of Benzene as a Bio-tar Model Compound over Ni–Fe/TiO2 Catalysts

Bio-tar formed during biomass gasification can cause the blockage or corrosion of pipelines and devices. Catalytic reforming through Ni-based catalysts is a potential method to achieve tar elimination, while carbon deposition is the main obstacle. In this study, the steam reforming of benzene was investigated over modified Ni/TiO2 catalysts, and the effects of metal promoters, reaction temperatures, and steam-to-carbon (S/C) molar ratios were explored. The results indicated that the Fe promoter was promising to simultaneously achieve the H2-rich gas production and suppress the carbon deposition over the catalyst. When the reaction temperature was 800 °C and the S/C molar ratio was 1.00, the benzene conversion ratio and the H2 yield, respectively, reached 96.31% and 102.53 mmol/gbenzene. Ni–Fe alloys were generated after the modification with the Fe promoter, which improved the dispersion of Ni components. Besides, the adsorption of H2O molecules was enhanced which favored the formation of lattice oxygen and accelerated the reforming of benzene. Furthermore, the accumulation of lattice oxygen promoted the oxidation of amorphous carbon and suppressed the formation of graphitic carbon, thereby protecting the active Ni sites from the coverage of the carbon layer. Therefore, the resistance of carbon deposition of the Fe-modified Ni/TiO2 catalyst was improved.

Effect of Aloe Vera Extract as Green Corrosion Inhibitor on Medium Carbon Steel in Sulphuric Acid Environment

Medium carbon steel is widely consumed by various industrial sectors due to its attractive set of mechanical properties and low cost, but it experiences deterioration when exposed to a corrosive environment. In the present study, Aloe Vera plant extract was studied as a green corrosion inhibitor for medium carbon steel in an acidic medium. The presence of inhibitive compounds in Aloe Vera plant extract was determined by FTIR. Moreover, the inhibition efficiency was determined through gravimetric analysis and electrochemical analysis. The results show that the Aloe Vera plant extract provided inhibition efficiency of more than 90% in both gravimetric and electrochemical analyses. Furthermore, the shift in polarization curves depicts that this plant extract is a mixed type inhibitor acting as an anodic and cathodic inhibitor. Overall, Aloe Vera plant extract provides excellent corrosion inhibition to medium carbon steel in the H2SO4 environment and can be used as a green corrosion inhibitor for mitigating internal corrosion of pipelines and storage tanks.

Study The Effect of Extract berry and mango leaves as a corrosion inhibitor of Cu, Carbon steel and Oil Pipelines.

For the corrosion of iron, copper and carbon steel in 1.0 M HCl and 1.0 M of HNO3 solution. The materials extracted from the berry and mango leaves when added in different concentrations to solutions of 1 molar of hydrochloric acid and nitric acid have shown remarkable and effective resistance to corrosion of iron, copper and carbon steel, as well as to the samples that we brought from the oil companies in Galo to study the extent of resistance of these materials to their corrosion and the use of these natural and extracted products of berry leaves and mango leaves for use as corrosion inhibitors for oil pipelines These natural products, which are available in the environment, have shown a great deal of effective resistance to corrosion of oil pipelines. The effect of both the temperature and the concentration of these substances on the corrosion of these minerals has been studied and the study has shown that they inhibit corrosion even at low concentrations of reach to 50 ppm.

Fast deoxygenation in a miniaturized annular centrifugal device

Corrosion of steel devices and pipelines by dissolved oxygen (DO) is of major concern in many industries. Miniaturization of devices is becoming increasingly important significant for process intensification and distributed production. In this context, we attempted to realize efficient deoxygenation of water using a miniaturized annular centrifugal device (MACD) based on the centrifugal force and microscale effect. The influence of different operational variables on the deoxygenation performance was studied. It was found that the optimal volume mass transfer coefficient and deoxygenation efficiency are 1.01 s−1 and 97.8 %, respectively. The gas-liquid flow patterns in the mixing cavity, liquid film thickness distribution and residence time of water in the separation cavity of the MACD were investigated. The mechanism of fast deoxygenation and phase separation in MACD is explained. Additionally, a dimensionless correlation was obtained to calculate the volume mass transfer coefficient, and the predicted values were in good agreement with the experimental data. The deoxygenation performance of the MACD was also compared to those of other similar rotating deoxygenation devices, proving that MACD has the advantages of efficient deoxygenation performance, fast phase separation, and low energy consumption.

Pipeline Corrosion Prediction Using the Grey Model and Artificial Bee Colony Algorithm

Pipeline corrosion prediction (PCP) is an important technology for pipeline maintenance and management. How to accurately predict pipeline corrosion is a challenging task. To address the drawback of the poor prediction accuracy of the grey model (GM(1,1)), this paper proposes a method named ETGM(1,1)-RABC. The proposed method consists of two parts. First, the exponentially transformed grey model (ETGM(1,1)) is an improvement of the GM(1,1), in which exponential transformation (ET) is used to preprocess the raw data. Next, dynamic coefficients, instead of background fixed coefficients, are optimized by the reformative artificial bee colony (RABC) algorithm, which is a variation of the artificial bee colony (ABC) algorithm. Experiments are performed on actual pipe corrosion data, and four different methods are included in the comparative study, including GM(1,1), ETGM(1,1), and three ETGM(1,1)-ABC variants. The results show that the proposed method proves to be superior for the PCP in terms of Taylor diagram and absolute error.

Acoustic emission monitoring of corrosion in steel pipes using Lamb-type helical waves

This paper is concerned with the monitoring of corrosion in steel pipelines using the acoustic emission (AE) technique. Large uniform corrosion in pipes causes significant wall-thickness loss, and the intensity of the AE activity is correlated with the severity of the corrosion. A new approach for considering the helical propagation of corrosion-related AE events is proposed. Specifically, it is suggested that a longer portion of conventional AE hit is considered to account for multiple arrivals of Lamb-type modes traveling helically in the circumference of the pipe known as helical guided waves (HGW). Using the recorded amplitude of these events, a qualitative corrosion monitoring approach is proposed using the b-value analysis. An accelerated corrosion test on a steel pipe instrumented with a network of AE sensors is carried out to validate the proposed approach. Moreover, a numerical study is performed to evaluate the energy variation of HGW during the corrosion process. Both experimental and numerical results suggest that helical Lamb-type AE has the potential to be utilized for corrosion monitoring.

An energy-aware and Q-learning-based area coverage for oil pipeline monitoring systems using sensors and Internet of Things

Pipelines are the safest tools for transporting oil and gas. However, the environmental effects and sabotage of hostile people cause corrosion and decay of pipelines, which bring financial and environmental damages. Today, new technologies such as the Internet of Things (IoT) and wireless sensor networks (WSNs) can provide solutions to monitor and timely detect corrosion of oil pipelines. Coverage is a fundamental challenge in pipeline monitoring systems to timely detect and resolve oil leakage and pipeline corrosion. To ensure appropriate coverage on pipeline monitoring systems, one solution is to design a scheduling mechanism for nodes to reduce energy consumption. In this paper, we propose a reinforcement learning-based area coverage technique called CoWSN to intelligently monitor oil and gas pipelines. In CoWSN, the sensing range of each sensor node is converted to a digital matrix to estimate the overlap of this node with other neighboring nodes. Then, a Q-learning-based scheduling mechanism is designed to determine the activity time of sensor nodes based on their overlapping, energy, and distance to the base station. Finally, CoWSN can predict the death time of sensor nodes and replace them at the right time. This work does not allow to be disrupted the data transmission process between sensor nodes and BS. CoWSN is simulated using NS2. Then, our scheme is compared with three area coverage schemes, including the scheme of Rahmani et al., CCM-RL, and CCA according to several parameters, including the average number of active sensor nodes, coverage rate, energy consumption, and network lifetime. The simulation results show that CoWSN has a better performance than other methods.

Model tests of the barrier measures on moisture and salt migration in soils subjected to freeze-thaw cycles

The migration and accumulation of chlorine salt in frozen soils will cause corrosion to the buried pipeline and seriously affect its service life. In order to investigate the effect of moisture and salt migration and accumulation on pipeline corrosion, three models of barrier measures were established using similar criteria, namely, non-saline soil replacement model (M1), non-saline soil replacement with impermeable geotextile barrier model (M2), and gravel replacement model (M3). Laboratory model tests were carried out to study the characteristics of moisture and salt migration and the barrier effect of different measures in response to freeze-thaw (F-T) cycles. The freezing depth is 38.6, 29.7, and 43.5 cm in three models. The volumetric moisture contents and salt concentrations are positively and negatively correlated with temperature, respectively. In M1, the maximum moisture contents decrease and increase obviously inside and outside of the upper boundary, with the variation rate of 11.7% and 11.1%. The maximum salt concentrations decrease by 7.7% and increase by 1.31 times, respectively. The concentration variations of the lower boundary are not obvious. They remain essentially constant in M2, i.e., 0.323 and 0.039 mol kg−1. The salt concentration in M3 has a far less reduction rate of 4.0%. Impermeable geotextile barrier and gravel replacement can prevent moisture and salt migration and corrosion to the pipeline. Concentration variation of M1 is primarily influenced by convection, salt expulsion and diffusion, while that of M2 outside the upper boundary is only influenced by convection, and M3 is caused by convection and salt expulsion. A combination of M3 and M2 measures are required when the buried pipeline is located above the freezing front and the water table is shallow. In other cases, M2 measures are chosen. The results can provide theoretical support and technical guidance for more economical and efficient construction and safe operation of the buried pipeline.

Corrosion mechanism and damage characteristic of Q235B steel under the effect of stray current in NS4 simulated soil solution

Dynamic direct current (DC) may cause severe electrochemical corrosion on buried steel pipelines near urban rail transits. In this paper, the corrosion behavior of Q235B steel under dynamic DC interference was carried out in NS4 simulated soil solution (NS4 solution) including potassium chloride (KCl), sodium bicarbonate (NaHCO3), calcium chloride (CaCl2), Magnesium sulfate heptahydrate (MgSO4.7 H2O) and deionized water. The electrochemical corrosion behaviors of Q235B steel in NS4 solution were studied by means of potentiodynamic polarization (Tafel curve) and electrochemical impedance spectroscopy (EIS) techniques. Dynamic DC was simulated by four types of applied current according to the leakage current rule of rail trains arriving at and departing from the platform. The results of Tafel curves showed that Q235B steel exhibits a decrease in corrosion resistance with increasing applied current density, and anodic reaction exhibited active dissolution controlled by charge transfer. EIS results indicated that Nyquist plots of samples included double capacitive arcs and exhibited Warburg impedance characteristics caused by the concentration gradient. Weightlessness measurement showed that the average corrosion rates of four types of samples were 1.0, 1.4, 2.0, and 2.5 g.cm−2. d−1, respectively. In addition, the corrosion morphology indicated that samples featured in pitting corrosion, which was correlated to applied dynamic DC values and counts, and corrosion products were Fe3O4 and Fe (OH)3. Finally, the study shows that corrosion of buried steel pipelines is related to rail train arriving types and counts.

An indirect detection strategy-assisted self-cleaning electrochemical platform for in-situ and pretreatment-free detection of endogenous H2S from sulfate-reducing bacteria (SRB)

The endogenous hydrogen sulfide (H2S) can be adopted as an indicator for the indirect detection of sulphate-reducing bacteria (SRB), which considered to be closely related to pipeline corrosion and human intestinal health. Unfortunately, the in-situ detection of endogenous H2S from SRB in the complex culture medium still faces huge challenges. Besides nonspecific adsorption from the culture medium of SRB, the problem of electrode passivation by produced elemental sulfur during electrochemical detection processes of H2S cannot be ignored. To address these challenges, herein a synergistic sensing platform based on self-cleaning electrode interface and indirect detection strategy (specific H2S-induced chemical reaction) is developed. This indirect sensing strategy-assisted self-cleaning electrochemical platform showed a relatively good linear response toward H2S in the range of 0.5 − 5 μM, and the corresponding limit of detection (LOD) was calculated to be 5.09 nM. More importantly, the satisfactory self-cleaning electrode interface in indirect detection system (with only a 4.10% decrease in signal over 50 electrochemical repeated cycles) showed the electrode surface not being disturbed by elemental sulfur. Furthermore, this good selectivity of the indirect detection strategy in combination with the reproducibility, stability, and antifouling activity of the self-cleaning interface, enabled a synergistic sensing platform to detect H2S directly in the complex culture medium of SRB without time-consuming sample pretreatments. Moreover, this proposed construction strategy of synergetic sensing platform could be explored to other endogenous molecules in complex environment based on different antifouling materials and specific reactions.

OPTIMAL REGULATION OF CATHODIC PROTECTION PLANT OPERATION ON THE BASIS OF RELIABILITY AND RESIDUAL LIFE

Corrosion of steel underground pipelines significantly reduces the service life, leading them to an emergency condition, in which further operation is impossible. The main methods of protecting such pipelinesare insulating coatings and electrochemical protection.Determination of the optimal operating parameters of the electrochemical protection system allows to increase the service life of protected objects, due to a decrease in the load on working objects. These approaches are mainly aimed at reducing energy consumption by determining their optimal output parameters of electrochemical protection equipment, subject to compliance with the requirements of RD for permissible values of the protective potential. However, optimal control algorithms do not directly take into account the actual technical state of the system and cannot provide information about its reliability.The average life of most existing pipelines is more than 20 years. The actual corrosion protection characteristics of such pipelines are significantly reduced in comparison with the initial. In view of this, there is a need to determine the reliability of the electrochemical protection system. Proposed methods for determining and evaluating the reliability indicators of electrochemical protection systems are aimed at building Markov models of the reliability of the object under study and determining its availability factor.The implementation of optimal control algorithms in conjunction with methods for assessing the reliability of electrochemical protection systems can make it possible to determine the time of trouble-free operation and identify the most “vulnerable” elements of the system.

Generation of iodinated trihalomethanes during chloramination in the presence of solid copper corrosion products

Copper water pipelines are widely used in water distribution systems, but the effects of solid copper corrosion products (CCPs) including CuO, Cu2O and Cu2(OH)2CO3 on the generation of iodinated trihalomethanes (I-THMs) during chloramination remain unknown. This study found that the formation of I-THMs during chloramination of humic acid (HA) was inhibited by the presence of CuO and Cu2O, but promoted with the addition of Cu2(OH)2CO3. The negative effect of CuO and Cu2O is mainly exerted by promoting the decay of both NH2Cl and HOI. Although Cu2(OH)2CO3 also accelerated the decomposition of NH2Cl and HOI, it was found that the complexes formed between Cu2(OH)2CO3 and HA facilitated, through carboxyl functional groups, the reaction between HA and HOI, leading to an enhancement of I-THM generation during chloramination, which was further confirmed by model compound experiments. Additionally, this study demonstrated that the effects of solid CCPs on I-THM generation during chloramination were solid CCP- and HA-concentration dependent, but almost unaffected by different initial I− and Br− concentrations. This study provides new insights into the health risks caused by the corrosion of copper water pipelines, especially in areas intruded by sea water.

Corrosion sensitivity analysis of pipelines in CO2 and H2S coexisting environment in the South China Sea

Abstract The purpose of the present work is to investigate the corrosion sensitivity of pipelines of oil and gas wells under complex environmental conditions (i.e., the primary and secondary relationship of the influence of different environmental factors on pipeline corrosion). The orthogonal experiment is introduced to design the experimental scheme. The weight loss method is employed to analyze the average corrosion rate of N80 steel under different environmental conditions. And then the scanning electron microscope is used to explore the surface and cross-section corrosion morphology of the corrosion products. Besides, the components of corrosion products are obtained by the energy spectrum analysis. The research results indicate that H2S partial pressure is the most sensitive factor to the corrosion of N80 pipeline and the influence of CO2 partial pressure on corrosion of N80 pipeline is weaker than Cl− concentration and temperature in the South China Sea. The study can help the oil drilling engineering search for direct and effective corrosion inhibitors under complex environmental conditions.

EXPERIMENTAL DETERMINATION OF THE CORROSION ENCRUSTATION VALUE IN STEEL GAS PIPELINES

Statement of the problem. The operating experience of gas pipelines and gas distribution networks shows that despite the almost complete protection of gas pipelines from corrosion by passive and active methods, more than 55-60 % of the damage detected during the diagnostics process is caused by damage of various corrosive nature. Finding the residual resource of pipelines is a pressing issue in the context of limited funding. The aim of the study is to conduct a detailed analysis of statistical data on internal corrosion of gas pipelines and to assess the magnitude of corrosion overgrowth of used gas pipelines using the developed method of diagnostics and assessment of the condition of pipes using a probabilistic approach to risk assessment.Results. The article presents the results of experimental measurement of the magnitude of corrosionovergrowth of steel gas pipelines, the regularities of changes in the diameter of the gas pipeline, the values of corrosion protrusions are obtained, the probability of their occurrence and their repeatability are numerically estimated. The processing of the measurement results of the overgrowth of steel gas pipelines was carried out using the methods of mathematical statistics, as a result, the probabilistic numerical characteristics of the investigated parameters of the gas pipeline were obtained. Conclusions. The histograms of the distribution of amplitudes, built on the basis of experimental data, confirm that the modal values of the heights of corrosion protrusions are shifted to the region of small values. Analysis of the results obtained allows us to conclude that the corrosion parameters are consistent with the Charlier probability distribution. When inspecting gas pipelines, the coefficient of variation exceeding 75 % indicates a decrease in the flow area of the pipe, a decrease in the quality of operation and the condition of gas pipelines.

Effect of ammonium salt on corrosion of pipelines and components in a crude oil distillation column: Electrochemical and AIMD studies

Experiments and theoretical calculations were conducted on the corrosion behavior and mechanism of SAE 1020 steel in NH4Cl solution. In-situ measurements demonstrate that temperature and concentration exert a great impact on corrosion and that the interfacial phenomena differ in early stages of immersion, while ex-situ measurements indicate the development of the corrosion product film from loose to denser. The Kelvin potential increases with temperature and concentration, exhibiting a significant characteristic of pitting corrosion. Additional kinetic trajectory simulation was conducted to combine surface reactions with hydrolysis of NH4+ to illustrate the essence of corrosion as a modification of the chemical bond.